SST_Stainless_Steel_Tank_Installation_Manual_en_08.2014_US.pdf

8/21/2019 SST_Stainless_Steel_Tank_Installation_Manual_en_08.2014_US.pdf

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Models: SST150-40SST250-65

SST300-80

SST450-119

Indirect Fired Water HeatersInstallation and Operating Manual

USC

CAUTION:The heat transfer medium must be water or othernontoxic fluid having a toxicity rating or class of 1, aslisted in Clinical Toxicology of Commercial Products,5th edition.The pressure of the heat transfer medium must belimited to a maximum of 30 PSIG by an approved

safety or relief valve.

WARNING:This manual must only be used by a trained heatinginstaller / service technician. Read all instructionsbefore installing. Perform steps in the order given.Failure to comply could result in severe personal

injury, death, or substantial property damage.


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2 | Indirect Fired Water Heaters Installation and Operating Manua

Installation & Operating Manual


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| 3Indirect Fired Water Heaters Installation and Operating Manual


Table of Contents

1 General Information 6

2 Pre-installation 7

3 Boiler Side Piping 8

4 Domestic Side (Tank) Piping 13

5 Wiring 17

6 Start-up and Check-out 18

7 Maintenance 19

8 Performance Data 21


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Explanation Of Symbols

Warnings

Warnings in this document are identified by awarning triangle printed against a grey

background.Keywords at the start of a warning indicatethe type and seriousness of the ensuing risk ifmeasures to prevent the risk are not taken.

The following keywords are defined and can be used inthis document:

DANGERindicates a hazardous situation which, if not

avoided, will result in death or serious injury.

WARNINGindicates a hazardous situation which, ifnot avoided, could result in death or serious injury.

CAUTIONindicates a hazardous situation which, if notavoided, could result in minor to moderate injury.

NOTICEis used to address practices not related topersonal injury.

Important information

Important information in cases where there is norisk of personal injury or material losses isidentified by the symbol shown on the left. It is

bordered by horizontal lines above and below thetext.

Please Read Before Proceeding

DANGER: Installer Read all instructionsbefore installing.

Perform steps in the order given. Have thisindirect water heater serviced/inspected by a

qualified service technician, at least annually.Failure to comply with the above could resultin severe personal injury, death or substantialproperty damage.

NOTICE:

When calling or writing about the appliance

Please have the indirect water heater modeland serial number from the indirect waterheater rating plate.

Consider piping and installation whendetermining appliance location.

Any claims for damage or shortage inshipment must be filled immediately againstthe transportation company by the consignee.

Factory warranty does not apply toappliances improperly installed or improperlyoperated.

DANGER:

If the information in this manual is not followedexactly, a fire or explosion may result causingproperty damage, personal injury or loss of life.This appliance MUST NOT be installed in anylocation where gasoline or flammable vapors arelikely to be present.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not useany phone in your home/building.

Evacuate the home/building immediately.

Immediately call your gas supplier. Follow the

gas suppliers instructions.

If you cannot reach your gas supplier, call thefire department.

Installation and service must be performed bya qualified installer, service agency, or the gassupplier.


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DANGER: HOT WATER CAN SCALD!

Water heated to temperatures for clotheswashing, dish washing, and other sanitizingneeds can scald and cause permanent injury.

Children, elderly, and infirm or physicallyhandicapped persons are more likely to bepermanently injured by hot water. Never leave

them unattended in a bathtub or shower. Neverallow small children to use a hot water tap ordraw their own bath.

If anyone using hot water in the building fits theabove description, or if state laws or local codesrequire certain water temperatures at hot watertaps, you must take special precautions: Use lowest possible temperature setting. Install some type of tempering device, such

as an automatic mixing valve, at hot watertap or water heater. Automatic mixing valvemust be selected and installed according tovalve manufacturers recommendations andinstructions.

Water passing out of drain valves may beextremely hot. To avoid injury: Make sure all connections are tight. Direct water flow away from any person

Protection Must Be Taken Against ExcessiveTemperature and Pressure! Installation of aTemperature & Pressure (T&P) relief valve isrequired.

DANGER:

Failure to adhere to the guidelines on this pagecan result in severe personal injury, death, orsubstantial property damage.

When Servicing the Indirect Water Heater -To avoid severe burns, allow the appliance to coolbefore performing maintenance.

Indirect water heater operation Should overheating occur or gas supply fail to shut off, donot turn off or disconnect electrical supply to circulator.Instead, shut off the gas supply at a location external tothe appliance.Do not use this appliance if any part has been underwater. The possible damage to a flooded appliance can beextensive and present numerous safety hazards. Anyappliance that has been under water must be replaced.

The following chart details the relationship of watertemperature and time with regard to scald injury and maybe used as a guide in determining the safest watertemperature for your applications.

APPROXIMATE TIME / TEMPERATURERELATIONSHIPS IN SCALDS

120 F More than 5 minutes

125 F 1 to 2 minutes

130 F About 30 seconds


140 F Less than 5 seconds

145 F Less than 3 seconds


155 F About 1 second


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1 General Information

The SST series indirect water heater (FIG. 1-1) is designedto generate domestic hot water in conjunction with a hotwater boiler using forced boiler water circulation. Thisindirect water heater consists of a 316L Stainless Steeltank in which a smooth 304L stainless steel coil is located(Table 1A). Boiler water is pumped through the coil andheats the water in the tank. This tank is not intended foruse in pool heating applications or for heating any fluidother than water. It is also not intended for use in gravityhot water heating systems.

Operating Restrictions: Maximum domestic hot water temperature is 194F. Maximum boiler water temperature is 210F. Maximum working pressure for the vessel tank is 150

psig.

Component Materials Table 1A

Component Material

Tank 316L Steel Stainless Steel

Coil 304L Stainless Steel

Insulation Polyurethane

Jacket Polypropylene/ABS

E

A

B

C

D

22.5

45

F

1-1/2 NPT (SEE NOTE 1)

1 NPT

1 NPT

AQUASTAT/SENSOR WELL

NOTES:

1. 1 NPT ON SST150-40. 1. RELIEF VALVE CONNECTION2. HOT WATER OUTLET3. BOILER WATER IN4. BOILER WATER OUT5. DRAIN/COLD WATER INLET

5

4

3

3/4 NPT 1

1-1/2 NPT (SEE NOTE 1) 2

SST150 - SST450

PART NO. A(in.)

B(in.)

C(in.)

D(in.)

E(in.)

F(in.)

SST150-40

SST250-65

SST300-80

SST450-119

3

3 1/4

3 1/4

3 1/4

8 1/4

9 1/4

9 1/4

9 1/4

25 1/4

28

31 3/4

48 1/2

52 1/2

61 3/4

60 1/4

56

60

70

69

20

24

24

28

WEIGHT FULL OF WATER

(lbs.)

515

820

921

1268

28

Figure 1-1

Single-Wall Heat Exchanger

National Standard Plumbing CodeSingle-wall heat exchangers in water heaters comply withthe National Standard Plumbing Code provided that: boiler water (including additives) is practically non-toxic,

having a toxicity rating or class of 1, as listed in ClinicalToxicology of Commercial Products, and

boiler water pressure is limited to a maximum of 30 psigby approved relief valve.

Uniform Plumbing CodeSingle-wall heat exchangers are permitted if they satisfy alof the following requirements:

1. The heat transfer medium is potable water or containsonly substances which are recognized as safe by theU.S. Food and Drug Administration.

2. The pressure of the heat transfer medium is maintainedless than the normal minimum operating pressure of thepotable water system.

3. The equipment is permanently labeled to indicate thatonly additives recognized as safe by the FDA shall beused in the heat transfer medium.

Other heat exchanger designs may be permitted whereapproved by local code.


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2 Pre-installation

1. The installation must conform to the instructions in thismanual and all applicable local, state, provincial, andnational codes, laws, regulations, and ordinances.Installations in Canada must conform to B149.2Installation Code.

2. Be certain the domestic water supply to the tank hasphysical and chemical characteristics that fall within thelimits shown in Table 2A. Where questions exist as tothe composition of the water on the job, a qualifiedwater treatment expert should be consulted.

CAUTION:Water with characteristics outside the limitsshown in Table 2A may severely shorten thelife of the tank due to corrosion. Damageto tanks in such cases is not covered underwarranty.

3. Read and understand all installation requirements inthis manual.

Water Chemistry Requirements Table 2A

Water used in the tank must have characteristics fallingwithin the following limits:

Characteristic Min. Max.

Ph 6.0 8.0

Chloride (PPM) -- 80

Locating the Tank1. Choose a location for your water heater centralized to

the piping system. You must also locate the SST waterheater where it will not be exposed to freezingtemperatures. Additionally, you will need to place thewater heater so that the controls, drain, and inlet/outlets are easily accessible. This appliance must not beinstalled outdoors, as it is certified as an indoorappliance, and must also be kept vertical on a levelsurface.

2. Keep distance between boiler and water heater to aminimum to:a. reduce piping heat lossb. provide minimal friction loss

3. Figure 1-1 on page 6 shows the weights of all the tanksfilled with water. Make sure that the location chosen forthe tank is capable of supporting it.

CAUTION:This appliance must be placed whereleakage from the temperature and pressure(T&P) relief valve, leakage from therelated piping, or leakage from the tank orconnections, will not result in damage to thesurrounding areas, or to the lower floors ofthe building. A water heater should always belocated in an area with a floor drain orinstalled in a drain pan suitable for waterheaters. The manufacturer shall not be heldliable for any such water damage. Damagecaused by the failure to properly install adrain pan or in an area with a drain is not theresponsibility of the manufacturer or Bosch

Thermotechnology Corp. (BTC).

4. The tank may be located some distance from the boilerprovided the pump is designed to provide the flowcalled for in Table 3B - Pressure Drop Values, throughthe coil. Also, the further the tank is from the boiler, thelonger the response of the boiler will be to a call fromthe tank zone. Insulate piping between the boiler andthe tank.

WARNING:Failure to properly support the tank could resultin property damage or personal injury.

Recommended ClearancesThe installation location must provide adequate clearancesfor servicing and proper operation of the water heater. A12 inch vertical clearance is recommended from the top ofthe water heater. A zero clearance is allowed for the sidesof the water heater. However, boiler and servicingclearances must be figured when locating the waterheater.


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3 Boiler Side Piping

Figures 3-1 thru 3-4 show typical boiler side piping forseveral common situations. Regardless of which system isused it is imperative that the flow rates called for in Table3B are developed through the coil. This requires properlysized piping and a properly sized pump. The system shownin FIGs 3-1 thru 3-4 are described below:

DHW PrioritizationThis piping system is designed to provide direct hot waterpriority over the other zones in the heating system. Whenthere is a Domestic Hot Water (DHW) call for heat, thecontroller will shut off the boiler circulator and activatethe domestic hot water circulator. Once the DHW demandis satisfied, the boiler circulator will be readjusted asdemand requires. The circulator must be large enough tomove the boiler water through the coils. Therecommended piping for a DHW priority system isdepicted in FIG. 3-1 and 3-2 using a GB142 wall hungboiler.

Zone with Circulator to AquastatThis system is like the circulator zone system on a straightheat job except that one of the zones goes to the tankinstead of radiation. As on any circulator zone systemcheck valves should be installed in each zone to preventunwanted circulation through zones which are not callingfor heat. Figure 3-3 illustrates typical circulator zone pipingwith a floor standing G115WS, G125BE, GB125BE, orG215 boiler.

.

Pressure Drop Values Table 3B

ModelWaterInlet(IN)

WaterOutlet(IN)

CoilConnection

(IN)

CoilLength

(FT)

Surfacearea

(SQ-FT)

Pressure Drop (FT/HD)

5GPM

8GPM

12GPM

16GPM

20GPM

SST150-40 1 1 1 30.8 10.0 0.41 1.04 2.34 4.16 6.49

SST250-65 1.5 1.5 1 41.5 13.5 0.61 1.57 3.53 6.27 9.80

SST300-80 1.5 1.5 1 41.5 13.5 0.61 1.57 3.53 6.27 9.80

SST450-119 1.5 1.5 1 67.3 22.0 0.73 1.87 4.22 7.50 11.71

Multiple Tank Connections (Boiler Side)Multiple tank installations must be done in the reverse-return manner. The reason for this is to create the samepressure drop (and therefore, the same flow) through thecoil of each tank. The boiler manifold piping must be sizedso that each coil has the flow rate called for in Table 3B.Because the pressure drop through tank coils varies fromsize to size, it is hard to predict the flow rate that will bedeveloped through each coil when two tanks of differentsizes are placed in the same manifold. For this reason it isbest not to mix tanks of different sizes in the same zone iftheir recovery is critical. A sample system is shown in FIG.3-4.

0

2

4

6

8

10

12

0 5 8 12 16 20

SST450-119

SST250-65/

SST300-80

SST150-40

Flow Rate

Head

Loss(Ft.ofHd.)

Pressure Drop Chart Table 3A


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DHWTANKPUMP

ANTI-SCALDMIXING VALVE

COLDWATER

IN

FROMSYSTEM

DRAIN( FIELD SUPPLY )

RECIRCULATIONPUMP

TANK SENSOR

HOTWATER

OUT

CHECK VALVE

SST series tank

DRAIN

POINT

Y-STRAINER

(RECOMMENDED)

GB 142

BOILER

AIRSEPARATOR

EXPANSIONTANK

BALL VALVE(TYPICAL)

SYSTEMPUMP

TOSYSTEM

SYSTEM SUPPLYSENSOR

PRESSURE RELIEFVALVE

AIRSEPARATOR

Figure 3-1 GB142 Boiler Low Loss Header piping and DHW priority

NOTICE:

Please note that these illustrations aremeant to show system piping concept only,the installer is responsible for all equipmentand detailing required by local codes.


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SST series tank

AIR SEPARATOR

ZONE #1

ZONE #2 ZONE #3 ZONE #4

DRAIN

POINT

MAKE UP WATER

BACKFLOWPREVENTER

PRESSUREREDUCING VALVE

PRESSUREGAUGE

EXPANSION

TANK

ZONE #1


ZONE PUMPS(TYPICAL)

TANK SENSOR

PRESSURE RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

DRAIN

( FIELD SUPPLY )

RECIRCULATIONPUMP

CHECK VALVE

GB 142

BOILER

BALL VALVE

COLDWATER

IN

HOTWATER

OUT


CHECK VALVE

PUMP

Figure 3-2 Piping diagram zoned with circulators and DHW priority

NOTICE:



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SST series tank

COLDWATER

IN

AIR SEPARATOR

ZONE #1


DRAIN

POINT

MAKE UP WATER

BACKFLOWPREVENTER

PRESSUREREDUCING VALVE

PRESSUREGAUGE

EXPANSIONTANK

ZONE #1


ZONE PUMPS(TYPICAL)

FLOW

CHECK

VALVE

TANK SENSOR

PRESSURE RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

DRAIN( FIELD SUPPLY )

HOTWATER

OUT


RECIRCULATIONPUMP

CHECK VALVE

BALL

VALVE

G115WS/G125BE/GB125BE

BALL

VALVE

DHWTANKPUMP

Figure 3-3 Piping diagram of floor standing boiler and DHW priority

NOTICE:



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HOT

WATEROUT

COLDWATER

IN


RECIRCULATIONPUMP

DRAIN

( FIELD SUPPLY )

PRESSURERELIEF VALVE(TYPICAL)

TANK SENSOR(TYPICAL)

CHECK VALVE

SST series tank SST series tank

FROMSYSTEM

DRAIN

POINT

Y-STRAINER

(RECOMMENDED)

GB 142

BOILER

AIRSEPARATOR

EXPANSIONTANK

BALL VALVE(TYPICAL)

SYSTEM

PUMP

TOSYSTEM

SYSTEM SUPPLYSENSOR

DHWTANKPUMP

AIRSEPARATOR

Figure 3-4 Multiple tank connections in reverse return

NOTICE:



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4 Domestic Side (Tank) Piping

Basic Domestic PipingFigure 4-2 shows typical domestic water piping for a tank.The function of the components shown are as follows:

a. Shut-off valves (recommended) - Used to isolate thetank for servicing.

b. Backflow Preventer (required by some codes) -Used to prevent water from backing out of the tank inthe event that inlet water pressure drops.

c. Expansion Tank (required when a backflowpreventer is used) - This expansion tank absorbs theincreased volume caused by heating water.

Use an expansion tank designed for use on domesticwater systems. Refer to the expansion tankmanufacturers literature for the proper size expansiontank to use.

NOTICE:

If an expansion tank is used, do not putany valves between the expansion tank andtank inlet.

d. Unions (optional) - Used to disconnect the tank in theunlikely event that this is necessary.

e. Drain (required) - Used to drain the tank for inspectionor servicing.

Multiple Tank Domestic Water PipingThe two pipe reverse return piping uses more pipe thanthe two pipe direct return piping, but the flow is morebalanced and even in the two pipe reverse return pipinglayout (see FIG. 3-4).

Each tank must have its own T&P valve. It is recommendedthat each tank be equipped with its own isolation valves,unions, and drains so that one tank may be removed fromthe system. If local codes require a backflow preventer,check with the appropriate authority to find out whether

one backflow preventer may be used for tanks or each tankmust be equipped with its own backflow preventer. If eachtank must have its own backflow preventer, each tank mustalso have its own expansion tank. If a common backflowpreventer is permitted, an expansion tank must be sized toaccommodate the expansion volume of all tanks.

Domestic Water Piping for Distant FixturesIn some cases the furthest fixture may be quite distantfrom the tank. Such an installation would result in anunacceptable delay before hot water reaches these distantfixtures. Even if all the fixtures are relatively close to thetank, the building owner may want hot water at all fixturesas soon as they are opened.

A solution to this problem is that a pipe runs from thefurthest fixture on each branch back to the return of thetank (reference FIG. 4-2). A small DHW recirculation pumpis mounted in this line and is wired so as to runcontinuously. A check valve in this line permits flowtowards the tank inlet only.

When no fixtures are drawing water, the DHW recirculationpump moves hot water from the tank to the end of thebranch just below the last fixture, then back to the inlet ofthe tank via the return pipe. When a fixture is opened, hotwater is already out in the branch very close to the fixtureand hot water appears at it almost immediately. The checkvalve prevents cold water in the tanks inlet pipe frompassing around the tank and heading directly to the fixture.

Because hot water is always circulating in the hot waterbranch the entire branch should be insulated to preventexcessive heat loss.


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Anti-scald Valves (Mixing Valves)Anti-scald valves used with water heaters are also calledtempering valves or mixing valves. An anti-scald valvemixes cold water in with the outgoing hot water to assurethat hot water reaching a building fixture is at atemperature low enough to be safe.

Usually, the maximum temperature of the outlet water willstay near the setting of the tank control. In some cases,however, hot water usage patterns can cause the outletwater temperature to rise significantly above the controlsetting.

The temperature of water going to the fixtures may bemore carefully controlled through the use of athermostatic mixing valve. This device blends a controlledamount of cold water with the hot water leaving the tankso that water at a more constant temperature exits themixing valve. Anti-scald mixing valve piping is illustrated inFIG.s 3-1 thru 3-4.

WARNING:

An anti-scald mixing valve does not eliminatethe risk of scalding.

Set the tank thermostat as low as practical.

Feel water before bathing or showering.

If anti-scald or anti-chill protection isrequired, use devices specifically designedfor such service. Install these devices inaccordance with their manufacturersinstructions.

Install Drain ValveDrain valve and fittings are supplied by others.

Standard Installation Install a tee connection at the domestic cold water inlet

(FIG. 4-1).

DRAIN

VALVE

Figure 4-1 Drain valve installed

Temperature & Pressure (T&P) Relief Valve

WARNING:

For protection against excessive temperaturesand pressure, install temperature and pressureprotective equipment required by local codes,

but not less than a combination temperatureand pressure (T&P) relief valve certified by anationally recognized testing laboratory thatmaintains periodic inspection of production oflisted equipment or materials as meeting therequirements for Relief Valves and AutomaticGas Shutoff Devices for Hot Water SupplySystems, ANSI Z21.22 and the Standard CAN1-4.4, Temperature, Pressure, Temperature andPressure Relief Valves and Vacuum Relief Valves.The combination temperature and pressurerelief valve shall be marked with a maximum setpressure not to exceed the maximum workingpressure of the water heater. The combination

temperature and pressure relief valve shall alsohave an hourly rated temperature steam BTUdischarge capacity not less than shown in Table4A.

Install the combination temperature andpressure relief valve into the opening providedand marked for this purpose on the waterheater. Failure to properly install the correcttemperature and pressure (T&P) relief valve canresult in a discharge of hot water that can causesevere personal injury or substantial propertydamage.

NOTICE:

Verify that the combination temperature andpressure (T&P) relief valve complies withlocal codes. If the combination temperatureand pressure relief valve does not complywith local codes, replace it with one that

does. Follow the installation instructions inthis section.


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Do not place a valve between the combination temperatureand pressure relief valve and the tank.

Determine T&P relief valve size by the followingspecifications, unless they conflict with local codes:

- SST150-40 - 3/4 NPT with a minimum AGA Rating of105,000 Btu/hr.

- SST250-65/300-80/450-119 - 3/4 NPT with aminimum AGA Rating of 200,000 Btu/hr.

NOTICE:

The SST series water heaters will absorb/store less than 200,000 Btu/hr whendomestic water outlet temperature is 210F

and boiler water supply temperature is240F. Listed outputs are based on ASMESection VIII Interpretation VIII-1-86-136.Check with local codes for applicability.

Minimum Relief Valve (AGA Rating) Table 4A

Model BTU/hr

SST150-40 105,000

SST250-65 200,000

SST300-80 200,000

SST450-119 200,000

Standard Installation Install the T&P relief valve in the connection marked

Relief Valve.

T&P Relief Valve Discharge PipingT&P relief valve discharge piping mustbe:

- made of material serviceable for a temperature of250F or greater.

- directed so that hot water flows away from all persons.- directed to a suitable place for disposal.- installed so as to allow complete draining of the T&Prelief valve and discharge line.

- terminated within 6 of the floor.

T&P relief valve discharge piping must notbe:- excessively long. Using more than two (2) elbows or 15feet of piping can reduce discharge capacity.

- directly connected to a drain. Refer to local codes.- subject to freezing.

DANGER:Do not install any valve between thetemperature and pressure (T&P) relief valveand the tank connection or on the T&P reliefvalve discharge piping. Improper placementand piping of T&P relief valve may result in adischarge of hot water that can cause severepersonal injury, death or substantial propertydamage.

WARNING:

The temperature and pressure (T&P) reliefvalve is not intended for constant duty,such as relief of pressure due to repeatednormal system expansion. Correct thiscondition by installing a properly sizedexpansion tank in a domestic water system.Refer to the expansion tank manufacturersinstallation instructions for proper sizing.Be advised, the hot discharge water fromthe temperature and pressure (T&P) reliefvalve, can cause severe personal injury, orsubstantial property damage.

WARNING:

Failure to install and maintain a new, listed"X "temperature and pressure (T&P)relief valve will release the manufacturerfrom any claim which might result fromexcessive temperature and pressures ordischarge of hot water.


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EXPANSIONTANK

UNION(TYPICAL)

SHOCK ARRESTOR

SHUTOFF VALVE

SHUTOFFVALVE

BACKFLOWPREVENTER

SHUTOFFVALVE

SHUTOFFVALVE


DRAIN( FIELD SUPPLY)

RECIRCULATIONPUMP

TO BOILER

FROM BOILER

CHECK VALVE

TANK SENSOR / AQUASTAT

SST SERIES TANK

Figure 4-2 Recommended domestic water piping

NOTICE:



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5 Wiring

Wiring using boiler sensor:

1. For wiring using boiler sensor, see boiler installationmanual.

Indirect Water Heater Controlled Using Aquastatand Zone Circulator / Valve:

1. Install Aquastat to tank. Aquastat control(Honeywell L4006 or equivalent) can be ordered fromyour local distributor.

2. Connect Aquastat to the zone controller for the IndirectWater Heater Zone.

3. Adjust Aquastat to the desired temperature.

INDIRECT TANK

AQUASTATCONTROL

Honeywell

L4006 or

equivalent

TEMPERATUREADJUSTMENT

WIRECONNECTIONS

ZONE CONTROL BOX

OR

ZONE VALVE

OR

ZONE CIRCULATOR

Figure 5-1 Wiring for zone control


18/28



6 Start-up and Check-out

1. Make sure the system is free of leaks and that air ispurged from the system.

CAUTION:

Fix any leaks found before proceeding further.Leakage from the boiler piping can result insevere damage to the boiler.

2. Many soldering fluxes contain Zinc Chloride which cancause severe corrosion damage to stainless steel. Aftercompleting all domestic water connections, flush theindirect water heater thoroughly before leaving theinstallation. This is particularly important if the indirectwater heater will be unused for an extended period oftime after installation. Flush the indirect water heater bydrawing at least three times its volume from the tank.

3. Make sure that all electrical connections are madecorrectly and that no exposed high voltage wiring ispresent.

4. Make sure that each zone valve or circulator operateswhen, and only when, its thermostat calls for heat. Leteach zone operate long enough to purge any remainingair from the system.

5. Set the indirect water heater to the desiredtemperature. Because hot water presents a scaldhazard, it is best to set the thermostat at 120F or lowerand raise it only if necessary to provide adequate hotwater.

6. Re-enable the burner and allow the boiler to operate.Make sure that the boiler shuts down when the indirectwater heater is satisfied.

7. After installation, installer to review with homeownertheir maintenance responsibilities and their frequencies,See Sec. 7 Maintenance.


19/28



7 Maintenance

The SST series indirect water heater system requiresannual inspection and maintenance to ensure a reliablesupply of hot water:

Make sure that the rest of the boiler and domestic waterpiping is free of leaks.

The indirect water heater depends upon the boiler for asource of heat and is therefore only as reliable as theboiler.

Make sure that the boiler is maintained in accordancewith the boiler manufacturers instructions.

If a water treatment system is required to keep the waterchemistry within the parameters shown in Table 2A (seeSection 2 - Pre-Installation), make sure that this systemis properly maintained.

Maintenance ScheduleAnnual service by a qualified service technician includesthe following:

1. Any procedure required by local codes.

2. Verify system pressure. Air venting procedure mayrequire adding water to bring boiler system up topressure, typically 12 psig.

3. Manually operate T&P relief valve at least once a year.This will release some hot water.

WARNING:

Before operating a temperature and pressure(T&P) relief valve, make sure no one is in frontof or around the T&P relief valve dischargepiping. Hot discharge water can cause severepersonal injury or substantial property damage.

4. Move operating lever to open position for a fewseconds and then move it back, allowing it to snapclosed. After the T&P relief valve is operated, if itcontinues to release water, close the cold water inletto the water heater immediately. Follow the draininginstructions, and replace the T&P relief valve. If theT&P relief valve weeps periodically, it may be due tothermal expansion. Do not plug the T&P relief valve ordischarge piping.

DANGER:

Plugging the temperature and pressure(T&P) relief valve or discharge piping cancause excessive pressure in the waterheater, resulting in severe personal injury,death, or substantial property damage.

Homeowner monthly maintenance to include:

1. Visually check valves, pipes, and fittings for leaks. Calla qualified service technician to repair leaks.

To Fill the Water Heater1. Close the water heater drain valve by turning the knob

clockwise.2. Open the cold water supply shutoff valve. Open

several hot water faucets to allow air to escape fromthe system.

3. When a steady stream of waterflows from the faucets,the water heater is filled. Close the faucets and checkfor water leaks at the water heater drain valve,combination temperature and pressure relief valve andthe hot and cold water connections.

DANGER:

Water from opened drain valves, unions andother connections may be extremely hot.To avoid severe personal injury, death, orsubstantial property damage:

Tighten all drain hose connections.

Direct hot water away from all persons.

To Drain the Water HeaterShould it become necessary to completely drain the waterheater, be sure to follow the steps below:

1. Disconnect the power supply to the heat source.Consult the plumbing professional or electric companyin your area for service.

2. Close the cold water supply shutoff valve.

3. Open the drain valve on the water heater.

4. Open a hot water faucet to allow air to enter the

system.Drain the water heater if it will be shut off and exposed tofreezing temperatures. Freezing water will expand anddamage the water heater.

If boiler water contains sufficient antifreeze, then onlythe domestic water needs to be drained.

If boiler water does not contain sufficient antifreeze, theboiler water and the domestic watermust be drained.


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If antifreeze is used in the boiler water, checkconcentration. Boiler water (including additives) must bepractically non-toxic, having a toxicity rating or class of 1,as listed in the Clinical Toxicology of CommercialProducts. A maximum 50/50 mixture of inhibitedpropylene glycol is recommended. Follow the antifreezemanufacturers instructions.

DANGER:

Do not use automotive, ethylene glycol orpetroleum-based antifreeze. These types ofantifreezes are toxic and could cause severepersonal injury or death if leakage into thedomestic hot water supply occurs. Do notuse any undiluted antifreeze. This can causesevere personal injury, death, or substantialproperty damage.


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8 Performance Data

Indirect Water Heater Table 8A

Model

PotableWater

VolumeGal.

HeatSourceWater

VolumeGal.

StandbyHeat Loss

F/hr

ContinuousDraw

RatingGal/hr

FirstHour

RatingGal/hr

MinimumHeat OutputRate from

Heat SourceBtu/hr

MinimumHeat

SourceFlow Rate

GPM

Tank HeatSourceFriction

Loss FeetW.C

SST150-40 40.0 1.6 0.9 181 208 115,000 14.0 4.5

SST250-65 67.0 1.9 0.7 263 327 154,000 14.0 5.7

SST300-80 81.5 2.1 0.6 266 347 171,000 14.0 5.7

SST450-119 113.4 3.2 0.5 322 431 199,000 14.0 6.5

These ratings were obtained with a heat source output andheat source flow rate as listed in the chart using theparameters of the Domestic Cold Water Inlet at 58F,Domestic Temperature Rise of 77F, and a BoilerTemperature Output of 180F. Other results will beobtained under different conditions.


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How to Properly Size Your Indirect Water HeaterUse the First Hour Rating (FHR) to properly size yourIndirect Water Heater. The First Hour Rating is the amountof hot water in gallons the heater can supply per hour(starting with a tank full of hot water), depending on tankcapacity, source of heat, and the size of the burner.

Estimate your peak hour demand as follows:

Determine what time of day (morning, noon, evening) youuse the most hot water in your home. Keep in mind thenumber of people living in your home.

Use the worksheet below to estimate your maximumusage of hot water during this one hour of the day -- thisis your peak hour demand. Note: The worksheet does notestimate total daily hot water usage.

The worksheet example shows a total peak hour demandof 165 gallons; therefore, this household would need awater heater with a First Hour Rating of no less than 165gallons.

Fixture Count GuideTo quickly estimate the minimum gallons of hot waterrequired based on a family size number of baths and hotwater appliances the First Hour Rating of the STS tankmust be equal to or exceed the total first hourrequirements.

Peak Hour Demand Worksheet

Description Fill in the Blank Example

40 Gallons for the first 2 people ___________________________ Gals. 40 Gals.

10 Gallons for each additional person ___________________________ Gals. 20 Gals.

20 Gallons for each bath after the first(consecutive bath)

___________________________ Gals. 20 Gals.

10 Gallons if dishwasher is used ___________________________ Gals. 10 Gals.

20 Gallons if clothes washer is used ___________________________ Gals. 20 Gals.

TOTAL ___________________________ Gals. 110 Gals.

Heavy Usage BufferUse if family members take longer than average showers, etc.

x 1.5 x 1.5

First Hour Rating ___________________________ Gals. 165 Gals.

Proceed to pages 23 & 24 of this manual to locate yourIndirect Water Heater and Boiler in the sizing charts. Usingthe First Hour Rating calculated in this worksheet, locateyour Indirect Water Heater and Boiler along with your FirstHour Rating. This will also determine the flow neededbetween the Indirect Water Heater and Boiler.


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First Hour Rating - 180F Boiler Loop Water (Universal Sizing - 45,000 - 295,000 Btu/hr) Table 8B

Model SST150-40 SST250-65

Circulator Flow

(GPM)

5 8 12 16 20 5 8 12 16 20

Domestic Outlet 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140

BoilerHeating

Capacity

45,000 122 97 122 97 153 128 153 128

60,000 150 118 150 118 183 149 183 149

75,000 179 138 179 138 213 170 213 170

95,000 217 165 217 165 217 165 252 197 252 197 252 197

115,000 217 165 252 189 252 189 252 189 291 226 291 226 291 226 291 226

140,000 252 189 267 200 282 211 286 208 305 235 319 245 338 259 338 259 338 259

165,000 267 200 282 211 286 213 305 235 319 245 356 271 386 293 388 294

195,000 319 245 356 271 386 293 388 294

225,000 356 271 386 293 388 294

260,000 388 294

295,000

Max BTU Input 92,998 112,972 123,331 129,574 132,764 118,488 129,139 146,864 163,768 167,924


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First Hour Rating - 180F Boiler Loop Water (Universal Sizing - 45,000 - 295,000 Btu/hr) Table 8C

Model SST300-80 SST450-119

Circulator Flow

(GPM)

5 8 12 16 20 5 8 12 16 20

Domestic Outlet 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140

BoilerHeatin

gCapacity

45,000 163 138 163 138 197 172 197 172

60,000 193 159 193 159 226 193 226 193

75,000 222 180 222 180 255 213 255 213

95,000 261 207 261 207 261 207 294 241 294 241 294 241

115,000 300 235 300 235 300 235 300 235 333 268 333 268 333 268 333 268

140,000 304 238 347 268 347 268 347 268 347 268 384 302 382 302 382 302 382 302 382 302

165,000 304 238 349 270 374 288 395 302 395 302 387 306 429 337 429 337 429 337 429 337

195,000 349 270 374 288 409 312 424 323 483 375 485 376 485 376 485 376

225,000 374 288 409 312 424 323 501 388 548 421 541 416

260,000 424 323 573 438 596 454

295,000 596 454

Max BTU Input 115,860 139,106 154,002 171,229 181,544 141,419 190,161 204,795 237,649 253,504


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Notes:


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United States and Canada

Bosch Thermotechnology Corp.

50 Wentworth Avenue

Londonderry, NH 03053

Tel: 603-552-1100

Fax: 603-965-7581

www.bosch-climate.us

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